[victory]

Not a pro detailer, but have plenty of experience in customer service/public relations. The way you handled the situation initially may have actually hurt you. Saying "I'm going to take this out on my second pass" could sound to the customer like "I ****ed up, just give me a second chance." The last thing I'd want to hear if i was a lay person in that situation is anything that sounds like "I want a do-over" because it sounds and looks like you did something wrong the first time. The message you needed to convey was "There is nothing wrong, this is an absolutely normal part of the process, just ask anyone who does this professionally"

Secondly, proceeding to beg him not to sue you and giving him your insurance information was essentially an admission of wrongdoing in his eyes and put you in a position of weakness. If it progressed to this point, you needed to be assertive and tell him that he really doesn't know what he's looking at, and that a lawsuit would only succeed in making him look foolish when you march out hoards of expert testimony on a topic he knows relatively little about.

Now, you need to call him, and whatever you do, do not be apologetic. Only make affirmative statements: "I want" not "i would like" and never admit there was or is a problem with the work you performed. Tell him outright that you understand why he is distressed, and explain to him that his satisfaction is the only thing you care about. Now, explain to him that neither he nor his neighbors are detailing professionals and they did not understand what they were looking at. Come up with a suitable analogy: For instance, what he is doing is a lot like threatening to sue a plastic surgeon because you don't like how you look halfway through the operation. Follow this by telling him that you want to complete the work you started and prove to him that the problem he perceived was non-existent and that when you finish he will be absolutely satisfied. Tell him if he thinks his car needs to be repainted now, then he has nothing to loose.

If he's still not convinced, it's time for some theatrics. Tell him that you think a lawsuit would only waste his time and money, because any detailer or body shop pro will testify that there is nothing wrong with the process you used on his paint and that, exactly as you told him, all that he needs to do is allow you to complete your work. Lets face it, this guys seems about as dense as they come. If he wants proof, tell him you are going to drive over to his place and that you will educate him using the paint on the hood your own car before you ever touch the paint on his again. Put some holograms on a small spot of your hood using a similar process you used on his car and buff them out as he watches and you explain exactly what's going on. All it costs you is a micron of clear for a very persuasive example that no even someone that thick headed can argue with.

Worst he can do is sue you and look like a jack@ss in small claims court.